Using IBM Maximo and Using IBM Maximo and Ivara EXP Enterprise to Ivara EXP Enterprise to Improve Asset Reliability Improve Asset Reliability p yp y& Performance at Oman & Performance at Oman Refining & PetrochemicalRefining & PetrochemicalRefining & PetrochemicalRefining & Petrochemical

Denis Marshment, Director, Asset Dynamics Asia‐ Project Manager in Oman

TopicsTopics

• Introducing Mina Al-Fahal Refinery (MAF)• Background to Project RCM at MAFg j• Implementation strategy• Examples of MAF implementation approach• Examples of MAF implementation approach• Next steps• Critical success factors

Mina  al Mina  al FahalFahal RefineryRefinery

• Part of Oman Refineries &Part of Oman Refineries & Petrochemicals Company (ORPC)

• Oman’s first refinery, commissioned in 1982

• Revamped in 1997 with total capacity of 107,000 bpd

• Employing:– 140 Operations– 60 Maintenance & Reliability

• Simple process producing:– Mogas– Mogas– Kerosene– Diesel– Light Residue (For further g (

processing)– LPG & Fuel Gas

Project ScopeProject Scope

• Diagnostic Report• Asset Prioritization.• Reliability Centered Maintenance (RCM2) Analysis

• Crude Unit• Platformer Unit

• Implementation of RCM

Challenges with this strategyChallenges with this strategy

• Deploying RCM across a large asset base• Working with limited resource availability• Converting RCM analysis into actual work• Implementing the new work practices in the field• Implementing the new work practices in the field• Tracking the benefits & monitoring performance• Sustaining the programmeSustaining the programme

RCM OutputsRCM Outputs

Condition & State

Condition & State

Human Senses85%

Human Senses85%

Descriptive80%

Descriptive80%

Failure Finding33%

Failure Finding33%M

Inspection92%

Inspection92%

Maintena

NumericNumericPredictive

25%Predictive

25%

ance Pro

Time BasedTime Based

Predictive Tech

Predictive Tech

Preventive 5%Preventive 5%

gram

Run to Failure33%

Run to Failure33%

We need effective tools for data collection & analysis

Redesign 4%Redesign 4%

data collection & analysis

IvaraIvara EXP EXP Execute

WorkIdentify the

Right Work at Ri ht Ti

Predict Asset Health

Maximo

Right TimeProcess Control Tools

Asset Management

Maximo

Asset Prioritization

Inspections

Work Order Management

Planning &Scheduling

Condition-based management

Rules-based diagnostic

RCMSc edu g

MRO Materials

Procurement

Tasks and Jobs

engine

Indicator-based job triggers

Performance Predictive Tools

Personnel &Trades

analysis and tracking

Applied RCM

Align Technologies to drive Asset IntelligenceAlign Technologies to drive Asset Intelligence

RCM PROJECT ACTIVITIESRCM PROJECT ACTIVITIES

• Commenced in July 2009• Asset Prioritization Analysis – all system ranked- August

2009.• RCM Analysis – 26 analysis completed – Dec 2009RCM Analysis 26 analysis completed Dec 2009

o Crude unit.o Platformer Unit.

• RCM Analysis Implemented into Ivara EXP– Jan 2010o 26 analysiso 7,000+ action planso 50,000+ indicators

Work Order IntegrationWork Order Integration

RCM

MaximoIvara EXP

Asset Reliability Program

O C diti-On Condition-Failure Finding-Schd Restoration-Corrective-Redesign-Run to Failure

Alarm Management

Work Orders

Work Orders

Condition Indicators

Check Sheets

Run to Failure

Status Updates

Maximo IntegrationMaximo Integration

RCMMaximoIvara EXP

Asset Reliability Program

-On Condition

RCMStatus Updates

Work Orders

-Failure Finding-Scheduled Restoration-Corrective-Redesign-Run to Failure

Alarm Management

Work Orders

Condition Indicators

Check Sheets

PMStandard

TasksStandard

Jobs Triggering Rule

Job Plan

SKF Aptitude IntegrationSKF Aptitude Integration

Vibration Reading

AptitudeVibration OPC Manager

OPC ServerVibration Monitoring Solution

OPC Manager (OPC Client)

Alarm management processAlarm management process

Alarms waiting to be acknowledgedAlarms waiting to be acknowledged

Using standard jobs to trigger pump Using standard jobs to trigger pump changechange oversoverschange change oversovers

Standard Task (Job Plan)(Job Plan)

Standard Job / TriggerStandard Job / Trigger(PM)

Asset information Asset information –– now now digitized and easily retrievabledigitized and easily retrievabledigitized and easily retrievabledigitized and easily retrievable

Calibration check sheetsCalibration check sheets

Calculating calibration span error for Calculating calibration span error for intervalinterval OptimisationOptimisationinterval interval OptimisationOptimisation

Custom data cards and attachments Custom data cards and attachments replace paper recordsreplace paper records

Smarter use of asset dataSmarter use of asset data

Drawings & other documents Drawings & other documents linked to the RCM processlinked to the RCM processlinked to the RCM processlinked to the RCM process

• Historical data is not lost – All Static history (sincehistory (since startup) stored in Ivara

Corrosion rate calculationsCorrosion rate calculations

Remaining Life CalculationsRemaining Life Calculations

Monitoring alarmsMonitoring alarms

Tracking operator complianceTracking operator compliance

Tracking trade complianceTracking trade compliance

Next stepsNext steps

C ti ith ll t t th f th l t• Continue with rollout to other areas of the plant• Increase usage by maintenance groups

I kill f li bili• Improve core skills of reliability support team• Continue to monitor compliance• Identify & quantify potential benefits

Critical success factorsCritical success factors

Top level management support & leadership• Top level management support & leadership• Motivated client team / flexible consulting team• Internal marketing campaignInternal marketing campaign• Emphasis on development of RCM templates• Fully leverage Ivara EXP capabilitiesy g p• Establish internal core team to support maintenance groups • Establish KPI’s to monitor compliance & performance

Th kTh kThank youThank you